US20190243339A1 - Additive manufacturing support device, additive manufacturing support method, and computer program product - Google Patents
Additive manufacturing support device, additive manufacturing support method, and computer program product Download PDFInfo
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- US20190243339A1 US20190243339A1 US16/343,408 US201616343408A US2019243339A1 US 20190243339 A1 US20190243339 A1 US 20190243339A1 US 201616343408 A US201616343408 A US 201616343408A US 2019243339 A1 US2019243339 A1 US 2019243339A1
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- B22F3/10—Sintering only
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- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
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- B23H7/02—Wire-cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
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Definitions
- the present invention relates to an additive manufacturing support device, an additive manufacturing support method, and an additive manufacturing support program for supporting additive manufacturing of a shaped article on a plate.
- Methods of manufacturing shaped articles include powder additive manufacturing in which a process of partially sintering or melting metal powder spread over a plate is repeated to manufacture a shaped article, as disclosed in Patent Literature 1.
- the spread metal powder and the plate are joined by sintering or melting, so that the plate and the shaped article are integrally formed.
- cutting is performed using a cutting apparatus exemplified by a wire electrical discharge machining apparatus. For that purpose, a separated portion that is a cutting allowance to be cut by the cutting apparatus is provided between the shaped article and the plate.
- the shape of the separated portion is commonly determined automatically by an additive manufacturing support device exemplified by a Computer Aided Manufacturing (CAM) device, based on shaped article data that is data indicating the three-dimensional shape of the shaped article.
- the automatic determination of the shape of the separated portion gives no consideration to the ease of cutting using the cutting apparatus.
- the determined shape may be a shape in which a machining allowance between a cutting part of the cutting apparatus and the separated portion that is an object to be cut changes greatly in a cutting process.
- a wire electrical discharge machining apparatus is used as the cutting apparatus, changes in the machining allowance between a wire and the separated portion lead to unstable cutting, causing such a problem that machining speed is reduced or wire breakage is likely to occur.
- the machining allowance is the length of a portion where the cutting part faces the object to be cut in the cutting process.
- the present invention has been made in view of the above, and an object thereof is to provide an additive manufacturing support device capable of proposing additive manufacturing that facilitates cutting of a separated portion using a cutting apparatus.
- the present invention relates to an additive manufacturing support device for supporting additive manufacturing of a shaped article on a plate.
- the additive manufacturing support device includes: a reader that reads shaped article data that is data indicating a three-dimensional shape of the shaped article; a first generator that generates primary data that is data indicating a three-dimensional shape of a primary separated portion provided in a region where a cutting part of a cutting apparatus passes between the plate and the shaped article; and a second generator that generates, based on a machining allowance between the cutting part and an object to be cut in a process in which the cutting part passes between the plate and the shaped article, secondary data for reducing change in the machining allowance.
- the additive manufacturing support device has an advantage of being able to propose additive manufacturing that facilitates cutting of a separated portion using a cutting apparatus.
- FIG. 1 is a perspective view illustrating a process of separating a shaped article additive manufactured by powder additive manufacturing from a plate.
- FIG. 2 is a perspective view illustrating the process of separating the shaped article additive manufactured by powder additive manufacturing from the plate.
- FIG. 3 is a perspective view illustrating the process of separating the shaped article additive manufactured by powder additive manufacturing from the plate.
- FIG. 4 is a perspective view illustrating the process of separating the shaped article additive manufactured by powder additive manufacturing from the plate.
- FIG. 5 is a perspective view illustrating an example of the shaped article formed on the plate by powder additive manufacturing.
- FIG. 6 is a diagram illustrating an example of a separated portion.
- FIG. 7 is a diagram illustrating an example of the separated portion.
- FIG. 8 is a diagram illustrating an example of the separated portion.
- FIG. 9 is a block diagram illustrating the functional configuration of an additive manufacturing support device according to a first embodiment of the present invention.
- FIG. 10 is a diagram illustrating a state in which a sampling pitch is set for a primary separated portion in the first embodiment.
- FIG. 11 is a diagram illustrating machining allowance information calculated by a machining allowance information calculator in the first embodiment.
- FIG. 12 is a diagram for comparing the shape of the primary separated portion and the shape of a secondary separated portion in the first embodiment.
- FIG. 13 is a diagram illustrating the hardware configuration of the additive manufacturing support device according to the first embodiment.
- FIG. 14 is a flowchart illustrating a procedure of generating secondary separated portion data by the additive manufacturing support device according to the first embodiment.
- FIG. 15 is a diagram illustrating a modification of the secondary separated portion generated by the additive manufacturing support device according to the first embodiment.
- FIG. 16 is a diagram illustrating a modification of the secondary separated portion generated by the additive manufacturing support device according to the first embodiment.
- FIG. 17 is a diagram illustrating a modification of the secondary separated portion generated by the additive manufacturing support device according to the first embodiment.
- FIG. 18 is a block diagram illustrating the functional configuration of an additive manufacturing support device according to a second embodiment of the present invention.
- FIG. 19 is a diagram illustrating a state in which the sampling pitch is set for the primary separated portion rotated with respect to the traveling direction of a wire.
- FIG. 20 is a diagram illustrating machining allowance information calculated at different rotation angles in the additive manufacturing support device according to the second embodiment.
- FIG. 21 is a flowchart illustrating a procedure of generating secondary separated portion data by the additive manufacturing support device according to the second embodiment.
- FIG. 22 is a block diagram illustrating the functional configuration of an additive manufacturing support device according to a third embodiment.
- FIG. 23 is a diagram illustrating the plate on which information indicating a desirable angle of the wire is displayed and the primary separated portion in the third embodiment.
- FIG. 24 is a diagram illustrating the plate on which information indicating a desirable traveling direction of the wire is displayed and the primary separated portion in the third embodiment.
- FIGS. 1 to 4 are perspective views illustrating a process of separating a shaped article additive manufactured by powder additive manufacturing from a plate.
- FIG. 1 illustrates a state in which a shaped article 2 is additive manufactured on a plate 1 by powder additive manufacturing in which metal powder is stacked in layers.
- the shaped article 2 is integrally formed on the plate 1 via a separated portion 3 .
- the separated portion 3 is cut with a wire 4 a as a cutting part of a wire electrical discharge machining apparatus 4 being a cutting apparatus, to separate the shaped article 2 from the plate 1 as illustrated in FIG. 3 .
- the separated portion 3 is cut with a certain amount thereof left on the shaped article 2 .
- the cutting apparatus is exemplified by a band saw other than the wire electrical discharge machining apparatus.
- the separated portion 3 which is provided between the plate 1 and the shaped article 2 , has the function of supporting the shaped article in an additive manufacturing process, as well as preventing damage to the shaped article during cutting.
- FIG. 5 is a perspective view illustrating an example of the shaped article 2 formed on the plate 1 by powder additive manufacturing. As illustrated in FIG. 5 , when the shaped article 2 has a shape with an upper portion larger than a lower portion like a T shape, the separated portion 3 supports overhanging portions 2 a of the shaped article 2 from below.
- FIGS. 6 to 8 are diagrams illustrating an example of the separated portion 3 .
- the separated portion 3 is provided for the purpose of avoiding damage to the shaped article 2
- the separated portion 3 is provided for the purpose of supporting the shaped article 2
- the separated portion 3 is an unnecessary portion for the shaped article 2 itself. Therefore, the separated portion 3 is formed in a shape with consideration given to the ease of removal in the finishing process.
- metal powder left in a powder state without becoming the separated portion 3 may be reusable for additive manufacturing. Therefore, the separated portion 3 is formed to have a minimum volume to leave more metal powder in a powder state.
- Examples of the shape of the separated portion 3 with consideration given to the ease of removal in the finishing process and the smallness of the volume include a lattice shape illustrated in FIG. 6 , a columnar shape illustrated in FIG. 7 , and a complicated geometric shape illustrated in FIG. 8 .
- Such a shape of the separated portion 3 is commonly generated automatically by an additive manufacturing support device exemplified by a CAM device, based on shaped article data that is data indicating the three-dimensional shape of the shaped article 2 generated by Computer Aided Design (CAD).
- CAD Computer Aided Design
- FIG. 9 is a block diagram illustrating the functional configuration of the additive manufacturing support device according to the first embodiment of the present invention.
- An additive manufacturing support device 10 generates separated portion data indicating the three-dimensional shape of the separated portion 3 , based on shaped article data on the shaped article 2 .
- the additive manufacturing support device 10 includes a reader 11 that reads in shaped article data.
- Shaped article data is data generated by the user, and may be stored in advance in a storage 12 described later, or may be stored in an external storage device connected to the additive manufacturing support device 10 by the user, or may be stored in a storage device provided in an external device connected to the additive manufacturing support device 10 .
- the additive manufacturing support device 10 includes a first generator 13 that generates separated portion data indicating the three-dimensional shape of the separated portion 3 , based on the three-dimensional shape indicated by the shaped article data.
- a second generator 14 described later also generates separated portion data.
- separated portion data generated by the first generator 13 is referred to as primary separated portion data, which is primary data
- a three-dimensional shape indicated by the primary separated portion data is referred to as a primary separated portion 31 , which is an object to be cut, for explanation.
- Separated portion data generated by the second generator 14 is referred to as secondary separated portion data, which is secondary data
- a three-dimensional shape indicated by the secondary separated portion data is referred to as a secondary separated portion 32 , which is an object to be cut, for explanation.
- the first generator 13 generates primary separated portion data in a predetermined pattern shape.
- Data indicating the predetermined pattern shape is stored in the storage 12 described later.
- Examples of the predetermined pattern shape include the lattice shape, the columnar shape, and the complicated geometric shape illustrated in FIGS. 6 to 8 .
- the lattice shape illustrated in FIG. 6 is the predetermined pattern shape will be described as an example.
- the additive manufacturing support device 10 includes a cutting part traveling direction acquirer 15 that acquires information indicating the traveling direction of the wire 4 a when cutting the separated portion 3 as illustrated in FIG. 2 .
- the traveling direction of the wire 4 a is determined by the posture in which the plate 1 is held in the wire electrical discharge machining apparatus 4 , for example.
- the posture in which the plate 1 is held in the wire electrical discharge machining apparatus 4 is determined by the shape of the plate 1 .
- a direction parallel to one side of the surface of the plate 1 on which the shaped article 2 is formed is the traveling direction of the wire 4 a.
- the additive manufacturing support device 10 includes a pitch setter 16 that sets a sampling pitch p in the process of cutting the primary separated portion as the object to be cut with the wire 4 a .
- FIG. 10 is a diagram illustrating a state in which the sampling pitch p is set for the primary separated portion in the first embodiment.
- the sampling pitch p is preferably smaller than the lattice width, and more preferably equal to or smaller than the diameter of the wire 4 a . If the sampling pitch p is too large, errors in machining allowance information described later become large, and if the sampling pitch p is too small, calculation time of machining allowance information becomes long.
- a so-called lamination pitch may be set as the sampling pitch p.
- the traveling direction of the wire 4 a is indicated by an arrow X.
- the additive manufacturing support device 10 includes a machining allowance extractor 17 that extracts a machining allowance at intervals of the sampling pitch p.
- the pitch setter 16 calculates a provisional cross-sectional area of a cut surface of the primary separated portion, based on the product of the sum total of machining allowances extracted at intervals of the sampling pitch p and the sampling pitch p.
- the machining allowance is the sum of the lengths of portions of the wire 4 a cutting the separated portion 3 when the wire 4 a performs cutting.
- the pitch setter 16 calculates the actual cross-sectional area of the cut surface of the primary separated portion, based on the primary separated portion data. When the difference between the provisional cross-sectional area of the cut surface of the primary separated portion and the actual cross-sectional area of the cut surface of the primary separated portion falls out of a predetermined tolerance, the pitch setter 16 sets the sampling pitch p to a smaller value.
- the additive manufacturing support device 10 includes a machining allowance information calculator 18 that calculates, based on the machining allowance extracted at intervals of the sampling pitch p, machining allowance information that is information on the machining allowance.
- FIG. 11 is a diagram illustrating the machining allowance information calculated by the machining allowance information calculator 18 in the first embodiment.
- the machining allowance information includes the largest machining allowance that is the largest of the machining allowances extracted at intervals of the sampling pitch p and the smallest machining allowance that is the smallest.
- the machining allowance information also includes the ratio between the largest machining allowance and the smallest machining allowance, and a mean machining allowance that is the mean of the machining allowances extracted at intervals of the sampling pitch p.
- the machining allowance information also includes a machining allowance standard deviation that is the standard deviation of the machining allowances extracted at intervals of the sampling pitch p.
- the machining allowance information calculator 18 provides the function of a deviation calculator that calculates the machining allowance standard deviation.
- the machining allowance becomes zero, and the machining allowance information cannot be appropriately calculated. Therefore, data equal to or lower than a certain threshold among the extracted machining allowances may be excluded to calculate the machining allowance information.
- the additive manufacturing support device 10 includes the second generator 14 that generates secondary separated portion data that is data indicating the three-dimensional shape of a secondary separated portion.
- the second generator 14 determines the shape of a secondary separated portion based on the machining allowance information calculated by the machining allowance information calculator 18 , and generates secondary separated portion data.
- the shape of the secondary separated portion is determined such that the machining allowance standard deviation becomes smaller.
- FIG. 12 is a diagram for comparing the shape of the primary separated portion and the shape of the secondary separated portion in the first embodiment.
- the second generator 14 determines the shape of a secondary separated portion 32 so that the machining allowance in the cutting process of the secondary separated portion 32 becomes constant at the mean machining allowance of the primary separated portion 31 .
- the primary separated portion 31 has the lattice shape
- the secondary separated portion 32 has a shape in which a plurality of pillar-shaped portions 32 a having a quadrangular cross-sectional shape are arranged.
- the mean machining allowance of the primary separated portion 31 is 4 mm.
- the machining allowance of the secondary separated portion 32 can be 4 mm, which is equal to the mean machining allowance of the primary separated portion 31 .
- the machining allowance in the cutting process of the secondary separated portion 32 can be made constant at 4 mm.
- FIG. 12 also illustrates a secondary separated portion 33 in which walls 33 a of a constant width are arranged in the extending direction of the wire 4 a.
- FIG. 11 also illustrates machining allowance information on the secondary separated portion 32 .
- the machining allowance standard deviation is zero.
- the primary separated portion 31 has a machining allowance standard deviation of 4.1, and the machining allowance changes greatly in the process of cutting the primary separated portion 31 .
- the additive manufacturing support device 10 includes a display 19 for displaying information, an input 20 to be operated by a user to enter information, and a storage 12 for storing information.
- a display 19 various types of information including the machining allowance information on the secondary separated portion 32 illustrated in FIG. 11 are displayed.
- the input 20 allows various types of information to be entered by the user operating it.
- the traveling direction of the wire 4 a may be entered by the user operating the input 20 .
- various types of information including the above-described tolerance and the pattern shape of the primary separated portion 31 are stored.
- FIG. 13 is a diagram illustrating the hardware configuration of the additive manufacturing support device 10 according to the first embodiment.
- the additive manufacturing support device 10 includes an arithmetic device 41 , a storage device 42 , a display device 43 , and a receiving device 44 .
- the arithmetic device 41 is exemplified by a Central Processing Unit (CPU).
- CPU Central Processing Unit
- the above-described functions of the reader 11 , the first generator 13 , the second generator 14 , the cutting part traveling direction acquirer 15 , the pitch setter 16 , the machining allowance extractor 17 , and the machining allowance information calculator 18 are implemented by the arithmetic device 41 .
- the storage device 42 is exemplified by semiconductor memory, a magnetic disk, or an optical disk.
- the above-described function of the storage 12 is implemented by the storage device 42 .
- programs that cause the arithmetic device 41 to provide the above functions are stored.
- the storage device 42 is also used as a primary storage area when the arithmetic device 41 executes the programs.
- the programs are exemplified by software, firmware, or a combination of software and firmware.
- the display device 43 is exemplified by a liquid crystal display.
- the above-described function of the display 19 is implemented by the display device 43 .
- the receiving device 44 is exemplified by a keyboard and a touch panel.
- the above-described function of the input 20 is implemented by the receiving device 44 .
- FIG. 14 is a flowchart illustrating a procedure of generating secondary separated portion data by the additive manufacturing support device 10 according to the first embodiment.
- step S 1 shaped article data is read (step S 1 ), and the traveling direction of the wire 4 a is acquired (step S 2 ).
- step S 3 primary separated portion data is generated (step S 3 ), and the sampling pitch p is set (step S 4 ).
- step S 5 machining allowance information is calculated (step S 5 ), and secondary separated portion data is generated (step S 6 ).
- one criterion in setting machining conditions in the wire electrical discharge machining apparatus 4 is the size of the machining allowance.
- machining condition setting may be difficult. For example, even when machining conditions suitable for a certain machining allowance are set, cutting with a machining allowance different from the machining allowance suitable for the current machining conditions occurs in the cutting process. Consequently, the cutting becomes unstable, and the machining speed is reduced or the breakage of the wire 4 a is likely to occur.
- the machining allowance standard deviation of the secondary separated portion 32 is smaller than that of the primary separated portion 31 . That is, when the secondary separated portion 32 is cut, changes in the machining allowance are smaller, and machining condition setting in the wire electrical discharge machining apparatus 4 is easier than when the primary separated portion 31 is cut.
- the generation of the secondary separated portion data in the above procedure facilitates machining condition setting in the wire electrical discharge machining apparatus 4 .
- the cutting can be stabilized and the machining speed can be maintained. That is, the secondary separated portion data, which is the secondary data, is data for reducing changes in the machining allowance.
- the machining allowance standard deviation of the secondary separated portion 32 does not necessarily need to be zero. If it is smaller than the machining allowance standard deviation of the primary separated portion 31 , machining condition setting can be facilitated. For example, when the spacing between the pillar-shaped portions 32 a is equal to or larger than a reference value, or when the pillar-shaped portions 32 a even in close contact with each other partly stick out of the shaped article 2 , a pillar-shaped portion 32 a may be added or deleted. Even in this case, if the standard deviation of the secondary separated portion 32 is smaller than the standard deviation of the primary separated portion 31 , the cutting is stabilized and the machining speed is maintained.
- the display of the machining allowance information illustrated in FIG. 10 on the display device 43 allows the user to view the cross-sectional area of the cut surface and changes in the machining allowance, which cannot be determined from the appearance of the separated portion 3 . This allows the user to have more information necessary for setting the machining conditions. Consequently, by having a lot of information, the user can easily set the machining conditions.
- FIGS. 15 to 17 are diagrams illustrating modifications of the secondary separated portion 32 generated in the additive manufacturing support device 10 according to the first embodiment.
- a solid portion 32 b that is solid is provided in the path of the wire 4 a .
- between the solid portion 32 b and the plate 1 and between the solid portion 32 b and the shaped article 2 are gap portions 32 c having space in a lattice shape, a columnar shape, and a geometric shape.
- the provision of the solid portion 32 b can eliminate residual gas or air and residual metal powder in a portion of the secondary separated portion 32 actually cut by the wire 4 a .
- the wire 4 a cuts the secondary separated portion 32 utilizing a discharge phenomenon. If gas or air is present in a discharge portion, the wire 4 a is likely to break due to vaporization explosion. If metal powder is left, the metal powder intervenes between the wire 4 a and the secondary separated portion 32 , and tends to cause a short circuit. When the wire 4 a is short-circuited, it locally generates high heat and tends to break. Therefore, the provision of the solid portion 32 b can prevent the occurrence of breakage of the wire 4 a .
- the thickness of the solid portion 32 b is desirably equal to or larger than the diameter of the wire 4 a.
- the machining allowance standard deviation can be set to zero to facilitate machining condition setting, stabilize cutting, and maintain manufacturing speed.
- FIG. 18 is a block diagram illustrating the functional configuration of an additive manufacturing support device according to a second embodiment of the present invention.
- the same reference numerals are assigned to the same components as those in the first embodiment without detailed explanations.
- An additive manufacturing support device 50 according to the second embodiment uses the primary separated portion 31 changed in the relative posture with respect to the plate 1 or the shaped article 2 as the secondary separated portion 32 as an object to be cut. Data indicating the three-dimensional shape of the secondary separated portion 32 is used as secondary data.
- the second generator 21 illustrated in FIG. 18 causes the machining allowance extractor 17 and the machining allowance information calculator 18 to extract a machining allowance and calculate machining allowance information at each of a plurality of angles through which the primary separated portion 31 is rotated in a cut plane with respect to the traveling direction of the wire 4 a.
- FIG. 19 is a diagram illustrating a state in which the sampling pitch p is set for the primary separated portion 31 rotated with respect to the traveling direction of the wire 4 a .
- the state illustrated in FIG. 10 is a state in which the primary separated portion 31 has been rotated 0° with respect to the traveling direction of the wire 4 a
- the state illustrated in FIG. 19 is a state in which the primary separated portion 31 has been rotated 30° with respect to the traveling direction of the wire 4 a.
- FIG. 20 is a diagram illustrating machining allowance information calculated at different rotation angles in the additive manufacturing support device according to the second embodiment.
- the rotation angle of the primary separated portion 31 is set to 30°
- the machining allowance standard deviation is the smallest
- the ratio between the largest machining allowance and the smallest machining allowance is also the smallest.
- a posture in which cutting is performed in the state illustrated in FIG. 19 is set as the secondary separated portion 32
- secondary separated portion data indicating the three-dimensional shape of the secondary separated portion 32 is generated by the second generator 21 as the secondary data.
- Extraction of a machining allowance and calculation of machining allowance information are performed at rotation angles ranging at least from 0 to 45°, desirably ranging from 0° to 360°.
- the extracted machining allowance and the machining allowance information are stored in the storage 2 .
- Criteria for determining the rotation angle of the secondary separated portion 32 are not limited to the smallness of the machining allowance standard deviation and the ratio between the largest machining allowance and the smallest machining allowance.
- FIG. 21 is a flowchart illustrating a procedure of generating secondary separated portion data by the additive manufacturing support device 50 according to the second embodiment.
- shaped article data is read in (step S 11 ), and the traveling direction of the wire 4 a is acquired (step S 12 ).
- primary separated portion data is generated (step S 13 ), and the sampling pitch p is set (step S 14 ).
- machining allowance information on the primary separated portion 31 at different rotation angles is calculated (step S 15 ), and secondary separated portion data is generated in a posture determined based on the machining allowance information (step S 16 ).
- the hardware configuration of the additive manufacturing support device 50 is the same as that in the first embodiment, and the function of the second generator 21 is implemented by the arithmetic device 41 illustrated in FIG. 13 .
- the secondary separated portion 32 can be cut in a posture in which the standard deviation is smaller.
- changes in the machining allowance are small, facilitating machining condition setting in the wire electrical discharge machining apparatus 4 .
- the posture of the primary separated portion data is determined in the above procedure, which facilitates machining condition setting in the wire electrical discharge machining apparatus 4 .
- the cutting can be stabilized and the machining speed can be maintained.
- data indicating the three-dimensional shape of the secondary separated portion 32 which is the secondary data, is data for reducing changes in the machining allowance.
- FIG. 22 is a block diagram illustrating the functional configuration of an additive manufacturing support device 60 according to a third embodiment.
- the second generator 22 causes the extraction of a machining allowance at each rotation angle and the calculation of the machining allowance as in the second embodiment, but does not generate secondary separated portion data with the posture of the primary separated portion 31 left at 0°. Instead, the second generator 22 sets data for displaying information indicating a desirable angle of the wire 4 a of the wire electrical discharge machining apparatus 4 , that is, at least one angle selected from a plurality of rotation angles, based on machining allowance information, on at least one of the plate 1 and the separated portion 3 , as secondary data.
- Some wire electrical discharge machining apparatus 4 can change the inclination of the wire 4 a by relatively moving wire guides 5 a and 5 b supporting the wire 4 a .
- the wire electrical discharge machining apparatus 4 can change the angle of the wire 4 a without changing the posture of the primary separated portion 31 .
- the cutting can be stabilized and the manufacturing speed can be maintained.
- the data to be displayed on at least one of the plate 1 and the separated portion 3 being the secondary data is data for reducing changes in the machining allowance.
- FIG. 23 is a diagram illustrating: the plate 1 on which information indicating a desirable angle of the wire 4 a is displayed; and the primary separated portion 31 , in the third embodiment. As illustrated in FIG. 23 , information indicating a desirable angle of the wire 4 a is displayed on the plate 1 with character information such as “30°”.
- information indicating a desirable angle of the wire 4 a is not limited to character information, and may be code information that can be read by a reader.
- the code information is exemplified by a bar code and a QR code (registered trademark).
- the wire electrical discharge machining apparatus 4 may be provided with a reader to cause it to read code information so that the wire guides 5 a and 5 b automatically move to set the wire 4 a at a suitable angle.
- Information indicating a desirable angle of the wire 4 a may be displayed on the display 19 .
- the hardware configuration of the additive manufacturing support device 60 is the same as that in the first embodiment, and the function of the second generator 22 is implemented by the arithmetic device 41 illustrated in FIG. 13 .
- FIG. 24 is a diagram illustrating the plate 1 on which information indicating a desirable traveling direction of the wire 4 a is displayed and the primary separated portion 31 in the third embodiment.
- the second generator 22 causes the plate 1 or the primary separated portion 31 to display a traveling direction of the wire 4 a to bring the mean machining allowance of the machining allowance information close to a predetermined suitable machining allowance.
- a desirable traveling direction of the wire 4 a is displayed with an arrow as symbol information on the plate 1 .
- information indicating a desirable traveling direction of the wire 4 a may be character information or code information.
- the predetermined suitable machining allowance may be stored in the storage 12 , or may be entered by the user through the input 20 .
- a machining allowance suitable for the cutting may be determined by conditions including the diameter of the wire 4 a .
- a suitable machining allowance is 30 mm to 50 mm.
- an arrow is displayed such that a direction parallel to the short side is the traveling direction of the wire 4 a .
- the above-described additive manufacturing support device 10 , 50 , or 60 may be implemented by a computer that creates shaped article data, or may be implemented by an additive manufacturing apparatus that receives input of shaped article data and performs additive manufacturing. Alternatively, it may be implemented by a server connected via a network to a computer that creates shaped article data or an additive manufacturing apparatus that performs additive manufacturing. Alternatively, it may be provided as programs that cause an arithmetic device to provide the above-described various functions, or a recording medium in which the programs are recorded.
Abstract
Description
- The present invention relates to an additive manufacturing support device, an additive manufacturing support method, and an additive manufacturing support program for supporting additive manufacturing of a shaped article on a plate.
- Methods of manufacturing shaped articles include powder additive manufacturing in which a process of partially sintering or melting metal powder spread over a plate is repeated to manufacture a shaped article, as disclosed in
Patent Literature 1. In the manufacturing of a shaped article using powder additive manufacturing like this, the spread metal powder and the plate are joined by sintering or melting, so that the plate and the shaped article are integrally formed. Thus, it is necessary to separate the plate and the shaped article by post-processing after forming the shaped article. To separate the plate and the shaped article, cutting is performed using a cutting apparatus exemplified by a wire electrical discharge machining apparatus. For that purpose, a separated portion that is a cutting allowance to be cut by the cutting apparatus is provided between the shaped article and the plate. -
- Patent Literature 1: Japanese Patent Application Laid-open No. 2007-16312
- However, the shape of the separated portion is commonly determined automatically by an additive manufacturing support device exemplified by a Computer Aided Manufacturing (CAM) device, based on shaped article data that is data indicating the three-dimensional shape of the shaped article. The automatic determination of the shape of the separated portion gives no consideration to the ease of cutting using the cutting apparatus. The determined shape may be a shape in which a machining allowance between a cutting part of the cutting apparatus and the separated portion that is an object to be cut changes greatly in a cutting process. Thus, when a wire electrical discharge machining apparatus is used as the cutting apparatus, changes in the machining allowance between a wire and the separated portion lead to unstable cutting, causing such a problem that machining speed is reduced or wire breakage is likely to occur. Note that the machining allowance is the length of a portion where the cutting part faces the object to be cut in the cutting process.
- The present invention has been made in view of the above, and an object thereof is to provide an additive manufacturing support device capable of proposing additive manufacturing that facilitates cutting of a separated portion using a cutting apparatus.
- To solve the above-mentioned problems and achieve the object, the present invention relates to an additive manufacturing support device for supporting additive manufacturing of a shaped article on a plate. The additive manufacturing support device includes: a reader that reads shaped article data that is data indicating a three-dimensional shape of the shaped article; a first generator that generates primary data that is data indicating a three-dimensional shape of a primary separated portion provided in a region where a cutting part of a cutting apparatus passes between the plate and the shaped article; and a second generator that generates, based on a machining allowance between the cutting part and an object to be cut in a process in which the cutting part passes between the plate and the shaped article, secondary data for reducing change in the machining allowance.
- The additive manufacturing support device according to the present invention has an advantage of being able to propose additive manufacturing that facilitates cutting of a separated portion using a cutting apparatus.
-
FIG. 1 is a perspective view illustrating a process of separating a shaped article additive manufactured by powder additive manufacturing from a plate. -
FIG. 2 is a perspective view illustrating the process of separating the shaped article additive manufactured by powder additive manufacturing from the plate. -
FIG. 3 is a perspective view illustrating the process of separating the shaped article additive manufactured by powder additive manufacturing from the plate. -
FIG. 4 is a perspective view illustrating the process of separating the shaped article additive manufactured by powder additive manufacturing from the plate. -
FIG. 5 is a perspective view illustrating an example of the shaped article formed on the plate by powder additive manufacturing. -
FIG. 6 is a diagram illustrating an example of a separated portion. -
FIG. 7 is a diagram illustrating an example of the separated portion. -
FIG. 8 is a diagram illustrating an example of the separated portion. -
FIG. 9 is a block diagram illustrating the functional configuration of an additive manufacturing support device according to a first embodiment of the present invention. -
FIG. 10 is a diagram illustrating a state in which a sampling pitch is set for a primary separated portion in the first embodiment. -
FIG. 11 is a diagram illustrating machining allowance information calculated by a machining allowance information calculator in the first embodiment. -
FIG. 12 is a diagram for comparing the shape of the primary separated portion and the shape of a secondary separated portion in the first embodiment. -
FIG. 13 is a diagram illustrating the hardware configuration of the additive manufacturing support device according to the first embodiment. -
FIG. 14 is a flowchart illustrating a procedure of generating secondary separated portion data by the additive manufacturing support device according to the first embodiment. -
FIG. 15 is a diagram illustrating a modification of the secondary separated portion generated by the additive manufacturing support device according to the first embodiment. -
FIG. 16 is a diagram illustrating a modification of the secondary separated portion generated by the additive manufacturing support device according to the first embodiment. -
FIG. 17 is a diagram illustrating a modification of the secondary separated portion generated by the additive manufacturing support device according to the first embodiment. -
FIG. 18 is a block diagram illustrating the functional configuration of an additive manufacturing support device according to a second embodiment of the present invention. -
FIG. 19 is a diagram illustrating a state in which the sampling pitch is set for the primary separated portion rotated with respect to the traveling direction of a wire. -
FIG. 20 is a diagram illustrating machining allowance information calculated at different rotation angles in the additive manufacturing support device according to the second embodiment. -
FIG. 21 is a flowchart illustrating a procedure of generating secondary separated portion data by the additive manufacturing support device according to the second embodiment. -
FIG. 22 is a block diagram illustrating the functional configuration of an additive manufacturing support device according to a third embodiment. -
FIG. 23 is a diagram illustrating the plate on which information indicating a desirable angle of the wire is displayed and the primary separated portion in the third embodiment. -
FIG. 24 is a diagram illustrating the plate on which information indicating a desirable traveling direction of the wire is displayed and the primary separated portion in the third embodiment. - Hereinafter, an additive manufacturing support device, an additive manufacturing support method, and an additive manufacturing support program according to embodiments of the present invention will be described in detail with reference to the drawings. Note that the embodiments are not intended to limit this invention.
- First, the separation of a shaped article formed by powder additive manufacturing from a plate will be described.
FIGS. 1 to 4 are perspective views illustrating a process of separating a shaped article additive manufactured by powder additive manufacturing from a plate.FIG. 1 illustrates a state in which ashaped article 2 is additive manufactured on aplate 1 by powder additive manufacturing in which metal powder is stacked in layers. As illustrated inFIG. 1 , theshaped article 2 is integrally formed on theplate 1 via aseparated portion 3. - Next, as illustrated in
FIG. 2 , theseparated portion 3 is cut with awire 4 a as a cutting part of a wire electricaldischarge machining apparatus 4 being a cutting apparatus, to separate theshaped article 2 from theplate 1 as illustrated inFIG. 3 . To avoid damage to theshaped article 2, theseparated portion 3 is cut with a certain amount thereof left on theshaped article 2. Then, by performing a finishing process of polishing theseparated portion 3 left on theshaped article 2, theseparated portion 3 is removed from theshaped article 2 as illustrated inFIG. 4 . Note that the cutting apparatus is exemplified by a band saw other than the wire electrical discharge machining apparatus. - The
separated portion 3, which is provided between theplate 1 and theshaped article 2, has the function of supporting the shaped article in an additive manufacturing process, as well as preventing damage to the shaped article during cutting.FIG. 5 is a perspective view illustrating an example of theshaped article 2 formed on theplate 1 by powder additive manufacturing. As illustrated inFIG. 5 , when theshaped article 2 has a shape with an upper portion larger than a lower portion like a T shape, the separatedportion 3 supports overhangingportions 2 a of theshaped article 2 from below. -
FIGS. 6 to 8 are diagrams illustrating an example of theseparated portion 3. Even when theseparated portion 3 is provided for the purpose of avoiding damage to theshaped article 2, and when theseparated portion 3 is provided for the purpose of supporting theshaped article 2, theseparated portion 3 is an unnecessary portion for theshaped article 2 itself. Therefore, theseparated portion 3 is formed in a shape with consideration given to the ease of removal in the finishing process. Of the spread metal powder, metal powder left in a powder state without becoming the separatedportion 3 may be reusable for additive manufacturing. Therefore, the separatedportion 3 is formed to have a minimum volume to leave more metal powder in a powder state. - Examples of the shape of the separated
portion 3 with consideration given to the ease of removal in the finishing process and the smallness of the volume include a lattice shape illustrated inFIG. 6 , a columnar shape illustrated inFIG. 7 , and a complicated geometric shape illustrated inFIG. 8 . Such a shape of the separatedportion 3 is commonly generated automatically by an additive manufacturing support device exemplified by a CAM device, based on shaped article data that is data indicating the three-dimensional shape of the shapedarticle 2 generated by Computer Aided Design (CAD). - Next, an additive manufacturing support device according to the first embodiment of the present invention will be described.
FIG. 9 is a block diagram illustrating the functional configuration of the additive manufacturing support device according to the first embodiment of the present invention. An additivemanufacturing support device 10 generates separated portion data indicating the three-dimensional shape of the separatedportion 3, based on shaped article data on the shapedarticle 2. - As illustrated in
FIG. 9 , the additivemanufacturing support device 10 includes areader 11 that reads in shaped article data. Shaped article data is data generated by the user, and may be stored in advance in astorage 12 described later, or may be stored in an external storage device connected to the additivemanufacturing support device 10 by the user, or may be stored in a storage device provided in an external device connected to the additivemanufacturing support device 10. - The additive
manufacturing support device 10 includes afirst generator 13 that generates separated portion data indicating the three-dimensional shape of the separatedportion 3, based on the three-dimensional shape indicated by the shaped article data. A second generator 14 described later also generates separated portion data. To distinguish them, separated portion data generated by thefirst generator 13 is referred to as primary separated portion data, which is primary data, and a three-dimensional shape indicated by the primary separated portion data is referred to as a primary separatedportion 31, which is an object to be cut, for explanation. Separated portion data generated by the second generator 14 is referred to as secondary separated portion data, which is secondary data, and a three-dimensional shape indicated by the secondary separated portion data is referred to as a secondary separatedportion 32, which is an object to be cut, for explanation. - The
first generator 13 generates primary separated portion data in a predetermined pattern shape. Data indicating the predetermined pattern shape is stored in thestorage 12 described later. Examples of the predetermined pattern shape include the lattice shape, the columnar shape, and the complicated geometric shape illustrated inFIGS. 6 to 8 . Here, a case where the lattice shape illustrated inFIG. 6 is the predetermined pattern shape will be described as an example. - The additive
manufacturing support device 10 includes a cutting part travelingdirection acquirer 15 that acquires information indicating the traveling direction of thewire 4 a when cutting the separatedportion 3 as illustrated inFIG. 2 . The traveling direction of thewire 4 a is determined by the posture in which theplate 1 is held in the wire electricaldischarge machining apparatus 4, for example. The posture in which theplate 1 is held in the wire electricaldischarge machining apparatus 4 is determined by the shape of theplate 1. When theplate 1 is a rectangular parallelepiped of a plate shape and is held as illustrated inFIG. 2 , a direction parallel to one side of the surface of theplate 1 on which the shapedarticle 2 is formed is the traveling direction of thewire 4 a. - The additive
manufacturing support device 10 includes apitch setter 16 that sets a sampling pitch p in the process of cutting the primary separated portion as the object to be cut with thewire 4 a.FIG. 10 is a diagram illustrating a state in which the sampling pitch p is set for the primary separated portion in the first embodiment. When the primary separatedportion 31 has a lattice shape, the sampling pitch p is preferably smaller than the lattice width, and more preferably equal to or smaller than the diameter of thewire 4 a. If the sampling pitch p is too large, errors in machining allowance information described later become large, and if the sampling pitch p is too small, calculation time of machining allowance information becomes long. When the diameter of thewire 4 a and the lattice width are unknown, the height of a layer formed by spreading and sintering metal powder at one time in additive manufacturing, a so-called lamination pitch may be set as the sampling pitch p. The traveling direction of thewire 4 a is indicated by an arrow X. - The additive
manufacturing support device 10 includes a machining allowance extractor 17 that extracts a machining allowance at intervals of the sampling pitch p. Thepitch setter 16 calculates a provisional cross-sectional area of a cut surface of the primary separated portion, based on the product of the sum total of machining allowances extracted at intervals of the sampling pitch p and the sampling pitch p. Here, the machining allowance is the sum of the lengths of portions of thewire 4 a cutting the separatedportion 3 when thewire 4 a performs cutting. - Further, the
pitch setter 16 calculates the actual cross-sectional area of the cut surface of the primary separated portion, based on the primary separated portion data. When the difference between the provisional cross-sectional area of the cut surface of the primary separated portion and the actual cross-sectional area of the cut surface of the primary separated portion falls out of a predetermined tolerance, thepitch setter 16 sets the sampling pitch p to a smaller value. - The additive
manufacturing support device 10 includes a machiningallowance information calculator 18 that calculates, based on the machining allowance extracted at intervals of the sampling pitch p, machining allowance information that is information on the machining allowance.FIG. 11 is a diagram illustrating the machining allowance information calculated by the machiningallowance information calculator 18 in the first embodiment. - As illustrated in
FIG. 11 , the machining allowance information includes the largest machining allowance that is the largest of the machining allowances extracted at intervals of the sampling pitch p and the smallest machining allowance that is the smallest. The machining allowance information also includes the ratio between the largest machining allowance and the smallest machining allowance, and a mean machining allowance that is the mean of the machining allowances extracted at intervals of the sampling pitch p. The machining allowance information also includes a machining allowance standard deviation that is the standard deviation of the machining allowances extracted at intervals of the sampling pitch p. Thus, the machiningallowance information calculator 18 provides the function of a deviation calculator that calculates the machining allowance standard deviation. In some cases, in a state where thewire 4 a is in contact with the primary separatedportion 31, the machining allowance becomes zero, and the machining allowance information cannot be appropriately calculated. Therefore, data equal to or lower than a certain threshold among the extracted machining allowances may be excluded to calculate the machining allowance information. - The additive
manufacturing support device 10 includes the second generator 14 that generates secondary separated portion data that is data indicating the three-dimensional shape of a secondary separated portion. The second generator 14 determines the shape of a secondary separated portion based on the machining allowance information calculated by the machiningallowance information calculator 18, and generates secondary separated portion data. In the first embodiment, the shape of the secondary separated portion is determined such that the machining allowance standard deviation becomes smaller. -
FIG. 12 is a diagram for comparing the shape of the primary separated portion and the shape of the secondary separated portion in the first embodiment. The second generator 14 determines the shape of a secondary separatedportion 32 so that the machining allowance in the cutting process of the secondary separatedportion 32 becomes constant at the mean machining allowance of the primary separatedportion 31. As illustrated inFIG. 12 , the primary separatedportion 31 has the lattice shape, while the secondary separatedportion 32 has a shape in which a plurality of pillar-shapedportions 32 a having a quadrangular cross-sectional shape are arranged. As illustrated inFIG. 11 , the mean machining allowance of the primary separatedportion 31 is 4 mm. If the pillar-shapedportions 32 a have a pillar shape measuring 1 mm per side, by arranging four pillar-shapedportions 32 a in the extending direction of thewire 4 a, the machining allowance of the secondary separatedportion 32 can be 4 mm, which is equal to the mean machining allowance of the primary separatedportion 31. With pillar-shapedportions 32 a aligned in the extending direction of thewire 4 a as one unit, by aligning a plurality of units without spacing in the traveling direction of thewire 4 a, the machining allowance in the cutting process of the secondary separatedportion 32 can be made constant at 4 mm. Furthermore, by spacing pillar-shapedportions 32 a in the extending direction of thewire 4 a in a unit in accordance with the shape of the shapedarticle 2, the secondary separated portion data indicating the shape of the secondary separatedportion 32 illustrated inFIG. 12 can be generated.FIG. 12 also illustrates a secondary separatedportion 33 in whichwalls 33 a of a constant width are arranged in the extending direction of thewire 4 a. -
FIG. 11 also illustrates machining allowance information on the secondary separatedportion 32. As illustrated inFIG. 11 , since the secondary separatedportion 32 has the constant machining allowance in the cutting process, the machining allowance standard deviation is zero. On the other hand, the primary separatedportion 31 has a machining allowance standard deviation of 4.1, and the machining allowance changes greatly in the process of cutting the primary separatedportion 31. - The additive
manufacturing support device 10 includes adisplay 19 for displaying information, aninput 20 to be operated by a user to enter information, and astorage 12 for storing information. On thedisplay 19, various types of information including the machining allowance information on the secondary separatedportion 32 illustrated inFIG. 11 are displayed. Theinput 20 allows various types of information to be entered by the user operating it. The traveling direction of thewire 4 a may be entered by the user operating theinput 20. In thestorage 12, various types of information including the above-described tolerance and the pattern shape of the primary separatedportion 31 are stored. -
FIG. 13 is a diagram illustrating the hardware configuration of the additivemanufacturing support device 10 according to the first embodiment. The additivemanufacturing support device 10 includes an arithmetic device 41, astorage device 42, a display device 43, and a receiving device 44. The arithmetic device 41 is exemplified by a Central Processing Unit (CPU). The above-described functions of thereader 11, thefirst generator 13, the second generator 14, the cutting part travelingdirection acquirer 15, thepitch setter 16, the machining allowance extractor 17, and the machiningallowance information calculator 18 are implemented by the arithmetic device 41. Thestorage device 42 is exemplified by semiconductor memory, a magnetic disk, or an optical disk. The above-described function of thestorage 12 is implemented by thestorage device 42. In thestorage device 42, programs that cause the arithmetic device 41 to provide the above functions are stored. Thestorage device 42 is also used as a primary storage area when the arithmetic device 41 executes the programs. The programs are exemplified by software, firmware, or a combination of software and firmware. The display device 43 is exemplified by a liquid crystal display. The above-described function of thedisplay 19 is implemented by the display device 43. The receiving device 44 is exemplified by a keyboard and a touch panel. The above-described function of theinput 20 is implemented by the receiving device 44. - A description will be given of a procedure of generating secondary separated portion data by the additive
manufacturing support device 10 described above.FIG. 14 is a flowchart illustrating a procedure of generating secondary separated portion data by the additivemanufacturing support device 10 according to the first embodiment. - First, shaped article data is read (step S1), and the traveling direction of the
wire 4 a is acquired (step S2). Next, primary separated portion data is generated (step S3), and the sampling pitch p is set (step S4). Next, machining allowance information is calculated (step S5), and secondary separated portion data is generated (step S6). - Here, one criterion in setting machining conditions in the wire electrical
discharge machining apparatus 4 is the size of the machining allowance. Thus, when the machining allowance changes in the cutting process, machining condition setting may be difficult. For example, even when machining conditions suitable for a certain machining allowance are set, cutting with a machining allowance different from the machining allowance suitable for the current machining conditions occurs in the cutting process. Consequently, the cutting becomes unstable, and the machining speed is reduced or the breakage of thewire 4 a is likely to occur. - In the first embodiment, as illustrated in
FIG. 11 , the machining allowance standard deviation of the secondary separatedportion 32 is smaller than that of the primary separatedportion 31. That is, when the secondary separatedportion 32 is cut, changes in the machining allowance are smaller, and machining condition setting in the wire electricaldischarge machining apparatus 4 is easier than when the primary separatedportion 31 is cut. Thus, the generation of the secondary separated portion data in the above procedure facilitates machining condition setting in the wire electricaldischarge machining apparatus 4. In addition, due to small changes in the machining allowance, the cutting can be stabilized and the machining speed can be maintained. That is, the secondary separated portion data, which is the secondary data, is data for reducing changes in the machining allowance. - Note that the machining allowance standard deviation of the secondary separated
portion 32 does not necessarily need to be zero. If it is smaller than the machining allowance standard deviation of the primary separatedportion 31, machining condition setting can be facilitated. For example, when the spacing between the pillar-shapedportions 32 a is equal to or larger than a reference value, or when the pillar-shapedportions 32 a even in close contact with each other partly stick out of the shapedarticle 2, a pillar-shapedportion 32 a may be added or deleted. Even in this case, if the standard deviation of the secondary separatedportion 32 is smaller than the standard deviation of the primary separatedportion 31, the cutting is stabilized and the machining speed is maintained. - Further, the display of the machining allowance information illustrated in
FIG. 10 on the display device 43 allows the user to view the cross-sectional area of the cut surface and changes in the machining allowance, which cannot be determined from the appearance of the separatedportion 3. This allows the user to have more information necessary for setting the machining conditions. Consequently, by having a lot of information, the user can easily set the machining conditions. -
FIGS. 15 to 17 are diagrams illustrating modifications of the secondary separatedportion 32 generated in the additivemanufacturing support device 10 according to the first embodiment. InFIGS. 15 to 17 , a solid portion 32 b that is solid is provided in the path of thewire 4 a. In the examples illustrated inFIGS. 15 to 17 , between the solid portion 32 b and theplate 1 and between the solid portion 32 b and the shapedarticle 2 aregap portions 32 c having space in a lattice shape, a columnar shape, and a geometric shape. - The provision of the solid portion 32 b can eliminate residual gas or air and residual metal powder in a portion of the secondary separated
portion 32 actually cut by thewire 4 a. Thewire 4 a cuts the secondary separatedportion 32 utilizing a discharge phenomenon. If gas or air is present in a discharge portion, thewire 4 a is likely to break due to vaporization explosion. If metal powder is left, the metal powder intervenes between thewire 4 a and the secondary separatedportion 32, and tends to cause a short circuit. When thewire 4 a is short-circuited, it locally generates high heat and tends to break. Therefore, the provision of the solid portion 32 b can prevent the occurrence of breakage of thewire 4 a. The thickness of the solid portion 32 b is desirably equal to or larger than the diameter of thewire 4 a. - When the shape of the solid portion 32 b is the shape of a rectangular parallelepiped having one side parallel to the traveling direction of the
wire 4 a, the machining allowance standard deviation can be set to zero to facilitate machining condition setting, stabilize cutting, and maintain manufacturing speed. -
FIG. 18 is a block diagram illustrating the functional configuration of an additive manufacturing support device according to a second embodiment of the present invention. The same reference numerals are assigned to the same components as those in the first embodiment without detailed explanations. An additivemanufacturing support device 50 according to the second embodiment uses the primary separatedportion 31 changed in the relative posture with respect to theplate 1 or the shapedarticle 2 as the secondary separatedportion 32 as an object to be cut. Data indicating the three-dimensional shape of the secondary separatedportion 32 is used as secondary data. - In the additive
manufacturing support device 50, the second generator 21 illustrated inFIG. 18 causes the machining allowance extractor 17 and the machiningallowance information calculator 18 to extract a machining allowance and calculate machining allowance information at each of a plurality of angles through which the primary separatedportion 31 is rotated in a cut plane with respect to the traveling direction of thewire 4 a. -
FIG. 19 is a diagram illustrating a state in which the sampling pitch p is set for the primary separatedportion 31 rotated with respect to the traveling direction of thewire 4 a. When the state illustrated inFIG. 10 is a state in which the primary separatedportion 31 has been rotated 0° with respect to the traveling direction of thewire 4 a, the state illustrated inFIG. 19 is a state in which the primary separatedportion 31 has been rotated 30° with respect to the traveling direction of thewire 4 a. -
FIG. 20 is a diagram illustrating machining allowance information calculated at different rotation angles in the additive manufacturing support device according to the second embodiment. In the example illustrated inFIG. 20 , when the rotation angle of the primary separatedportion 31 is set to 30°, the machining allowance standard deviation is the smallest, and the ratio between the largest machining allowance and the smallest machining allowance is also the smallest. Thus, a posture in which cutting is performed in the state illustrated inFIG. 19 is set as the secondary separatedportion 32, and secondary separated portion data indicating the three-dimensional shape of the secondary separatedportion 32 is generated by the second generator 21 as the secondary data. Extraction of a machining allowance and calculation of machining allowance information are performed at rotation angles ranging at least from 0 to 45°, desirably ranging from 0° to 360°. The extracted machining allowance and the machining allowance information are stored in thestorage 2. Criteria for determining the rotation angle of the secondary separatedportion 32 are not limited to the smallness of the machining allowance standard deviation and the ratio between the largest machining allowance and the smallest machining allowance. - Next, a description will be given of a procedure of generating secondary separated portion data by the additive
manufacturing support device 50.FIG. 21 is a flowchart illustrating a procedure of generating secondary separated portion data by the additivemanufacturing support device 50 according to the second embodiment. First, shaped article data is read in (step S11), and the traveling direction of thewire 4 a is acquired (step S12). Next, primary separated portion data is generated (step S13), and the sampling pitch p is set (step S14). Next, machining allowance information on the primary separatedportion 31 at different rotation angles is calculated (step S15), and secondary separated portion data is generated in a posture determined based on the machining allowance information (step S16). - The hardware configuration of the additive
manufacturing support device 50 is the same as that in the first embodiment, and the function of the second generator 21 is implemented by the arithmetic device 41 illustrated inFIG. 13 . - In the second embodiment, the secondary separated
portion 32 can be cut in a posture in which the standard deviation is smaller. Thus, changes in the machining allowance are small, facilitating machining condition setting in the wire electricaldischarge machining apparatus 4. Accordingly, the posture of the primary separated portion data is determined in the above procedure, which facilitates machining condition setting in the wire electricaldischarge machining apparatus 4. In addition, due to small changes in the machining allowance, the cutting can be stabilized and the machining speed can be maintained. Also in the second embodiment, data indicating the three-dimensional shape of the secondary separatedportion 32, which is the secondary data, is data for reducing changes in the machining allowance. -
FIG. 22 is a block diagram illustrating the functional configuration of an additivemanufacturing support device 60 according to a third embodiment. The same reference numerals are assigned to the same components as those in the first and second embodiments without detailed explanations. In the third embodiment, the second generator 22 causes the extraction of a machining allowance at each rotation angle and the calculation of the machining allowance as in the second embodiment, but does not generate secondary separated portion data with the posture of the primary separatedportion 31 left at 0°. Instead, the second generator 22 sets data for displaying information indicating a desirable angle of thewire 4 a of the wire electricaldischarge machining apparatus 4, that is, at least one angle selected from a plurality of rotation angles, based on machining allowance information, on at least one of theplate 1 and the separatedportion 3, as secondary data. Some wire electricaldischarge machining apparatus 4 can change the inclination of thewire 4 a by relatively moving wire guides 5 a and 5 b supporting thewire 4 a. When cutting is performed using the wire electricaldischarge machining apparatus 4 like this, by changing the angle of thewire 4 a without changing the posture of the primary separatedportion 31, the cutting can be stabilized and the manufacturing speed can be maintained. Also in the third embodiment, the data to be displayed on at least one of theplate 1 and the separatedportion 3 being the secondary data is data for reducing changes in the machining allowance. -
FIG. 23 is a diagram illustrating: theplate 1 on which information indicating a desirable angle of thewire 4 a is displayed; and the primary separatedportion 31, in the third embodiment. As illustrated inFIG. 23 , information indicating a desirable angle of thewire 4 a is displayed on theplate 1 with character information such as “30°”. - Note that information indicating a desirable angle of the
wire 4 a is not limited to character information, and may be code information that can be read by a reader. The code information is exemplified by a bar code and a QR code (registered trademark). The wire electricaldischarge machining apparatus 4 may be provided with a reader to cause it to read code information so that the wire guides 5 a and 5 b automatically move to set thewire 4 a at a suitable angle. Information indicating a desirable angle of thewire 4 a may be displayed on thedisplay 19. - The hardware configuration of the additive
manufacturing support device 60 is the same as that in the first embodiment, and the function of the second generator 22 is implemented by the arithmetic device 41 illustrated inFIG. 13 . -
FIG. 24 is a diagram illustrating theplate 1 on which information indicating a desirable traveling direction of thewire 4 a is displayed and the primary separatedportion 31 in the third embodiment. As illustrated inFIG. 24 , the second generator 22 causes theplate 1 or the primary separatedportion 31 to display a traveling direction of thewire 4 a to bring the mean machining allowance of the machining allowance information close to a predetermined suitable machining allowance. In the third embodiment, a desirable traveling direction of thewire 4 a is displayed with an arrow as symbol information on theplate 1. Note that information indicating a desirable traveling direction of thewire 4 a may be character information or code information. The predetermined suitable machining allowance may be stored in thestorage 12, or may be entered by the user through theinput 20. - In cutting by the wire electrical
discharge machining apparatus 4, a machining allowance suitable for the cutting may be determined by conditions including the diameter of thewire 4 a. In general, a suitable machining allowance is 30 mm to 50 mm. As illustrated inFIG. 24 , when the long side of the primary separatedportion 31 of a rectangular shape is 50 mm and the short side is 15 mm, an arrow is displayed such that a direction parallel to the short side is the traveling direction of thewire 4 a. Thus, by performing cutting, in an actual cutting process, with a machining allowance closer to a suitable machining allowance, stabilized cutting and improved manufacturing speed can be achieved. - The above-described additive
manufacturing support device - The configuration described in the above embodiments illustrates an example of the subject matter of the present invention, and can be combined with another known art, and can be partly omitted or changed without departing from the scope of the present invention.
-
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- 1 plate; 2 shaped article; 2 a overhanging portion; 3 separated portion; 4 wire electrical discharge machining apparatus; 4 a wire; 5 a, 5 b wire guide; 10, 50, additive manufacturing support device; 11 reader; 12 storage; 13 first generator; 14, 21, 22 second generator; 15 cutting part traveling direction acquirer; 16 pitch setter; 17 machining allowance extractor; 18 machining allowance information calculator; 19 display; 20 input; 31 primary separated portion; 32 secondary separated portion; 32 a pillar-shaped portion; 32 b solid portion; 32 c gap portion; 41 arithmetic device; 42 storage device; 43 display device; 44 receiving device.
Claims (16)
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PCT/JP2016/089107 WO2018123023A1 (en) | 2016-12-28 | 2016-12-28 | Laminate shaping support device, laminate shaping support method, and laminate shaping support program |
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US20190243339A1 true US20190243339A1 (en) | 2019-08-08 |
US10705510B2 US10705510B2 (en) | 2020-07-07 |
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JP (1) | JP6316517B1 (en) |
CN (1) | CN110099766B (en) |
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US20210046666A1 (en) * | 2019-08-16 | 2021-02-18 | United Grinding Group Management AG | Processing module for a building panel |
CN112719290A (en) * | 2020-12-09 | 2021-04-30 | 北京航星机器制造有限公司 | Method and system for manufacturing workpiece |
WO2021217044A1 (en) * | 2020-04-23 | 2021-10-28 | Saint-Gobain Abrasives, Inc. | System and method for conducting an abrasive operation |
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JP2022175662A (en) * | 2021-05-14 | 2022-11-25 | トヨタ自動車株式会社 | Method for manufacturing laminated molded article |
DE102021214633A1 (en) | 2021-12-17 | 2023-06-22 | Robert Bosch Gesellschaft mit beschränkter Haftung | Procedure for handling data sets for the series production of additively manufactured components |
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- 2016-12-28 WO PCT/JP2016/089107 patent/WO2018123023A1/en active Application Filing
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US20210046666A1 (en) * | 2019-08-16 | 2021-02-18 | United Grinding Group Management AG | Processing module for a building panel |
WO2021217044A1 (en) * | 2020-04-23 | 2021-10-28 | Saint-Gobain Abrasives, Inc. | System and method for conducting an abrasive operation |
CN112719290A (en) * | 2020-12-09 | 2021-04-30 | 北京航星机器制造有限公司 | Method and system for manufacturing workpiece |
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CN110099766A (en) | 2019-08-06 |
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JPWO2018123023A1 (en) | 2019-01-10 |
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WO2018123023A1 (en) | 2018-07-05 |
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